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RAILS

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TŘINECKÉ ŽELEZÁRNY, a.s. Třinec-Staré Město Průmyslová 1000, 739 70 Třinec Czech Republic tel.: +420-558-531 111 fax: +420-558-331 831 www.trz.cz

MORAVIA STEEL a.s. Třinec-Staré Město Průmyslová 1000, 739 70 Třinec Czech Republic tel.: +420-558-537 301, +420-558-535 865 fax: +420-558-324 355 www.moravia-steel.cz

TRINEC-CMC LTD. 5 Bradwall Court, Bradwall Road, Sandbach Cheshire, CW11 1GE, England tel.: +44-1270-759 441 fax: +44-1270-529 017 e-mail: ncauldwell@commercialmetals.com abudge@commercialmetals.com

CMC TRINEC STAHLHANDEL GMBH Gewerbepark Herweg, Cliev 19 D - 515 15 Kuerten Deutschland tel.: +49 2207 847 70 fax: +49 2207 847 777

CMC TRINEC STAHLHANDEL GMBH – OBERBAU Kardinal-Hengsbach-Strasse 4, 46236 Bottrop Deutschland tel.: +49-2041-107040, +49-2041-107041 fax: +49-2041-107042 e-mail: cmt.oberbau@t-online.de

MORAVIA STEEL SLOVENIJA D.O.O. Valvazorjeva 14, 3000 Celje, Slovenija tel.: +386 40 785 785 fax: +386 34 918 261 e-mail: MSSLOVENIJA@moravia-steel.si

MORAVIA STEEL ITALIA S.R.L. Via Niccolini 26, 20154 Milano, Italy tel.: +39-02-349 381 54 fax: +39-02-318 099 37 e-mail: info@moraviasteelitalia.com

MORAVIA STEEL IBÉRIA, S.A. Campo Grande, n 35 –9 A,1700 Lisboa Portugal tel.: +351 217 826 250 fax: +351 217 937 985 e-mail: moravia.s.iberia@mail.telepac.pt


CONTENT

03 THE MANUFACTURE OF RAILS

04 TESTING, CLASSIFICATION, AND ACCEPTANCE

05 RESEARCH AND DEVELOPMENT

06 TECHNICAL DATA AND PARAMETERS

11 SALES

12 CONTACTS


RAILS

T H E M A N U FA C T U R E O F R A I L S

THE MANUFACTURE OF RAILS The manufacture of rails is one of the principal manufacturing programs and, therefore, an extraordinary attention is paid to it in view of the quality control system. The following certificates have been granted by the company TĂœV NORD: the quality control system according to ISO 9001:2000, environmental management system according to ISO 14001:2004 and the quality management system according to VDA 6, part 1. The granted certificates are covering the complete production process, starting from the processing of an inquiry, proposal and sales contract, through the technological and technical development and the proper production up to the inspection and testing of finished products and services for the clients. The production process is tracked by means of check points and corresponding procedures to assure in all circumstances the quality of products which have to comply with customer’s demands, contracts, standards and other specific requirements. Achieving the required quality parameters of rails is proved by granting of the certificate Q1 and HPQ by the company Deutsche Bahn AG.

3


RAILS

T E S T I N G , C L A S S I F I C AT I O N , A N D A C C E P TA N C E

TESTING, CLASSIFICATION, AND ACCEPTANCE The fulfillment of the qualitative demands with regard to material properties and observance of the geometrical parameters of the produced rails is assured by the advanced system of testing and measurements followed by the acceptance. The ultrasonic testing of the internal homogeneity, testing of surface defects by using vortical flow and laser testing of the rail section is practiced during the production flow. After that the rails are tested in the independent test room where following practices are proceeded: • Mechanical properties are tested • Macroscopic and microscopic evaluationsare performed • Surface is checked • Rail shape is checked by means of pass templates Based on the client’s request also other tests can be performed (impact test, hardness test, oxygen content etc.). The individual results and values are documented and certified.

4


RAILS

R E S E A R C H A N D D E V E LO P M E N T

RESEARCH AND DEVELOPMENT Further development aims at the area of material innovation and profile innovation. The development projects are going on in accordance with the customers’ demands, the technical progress and advance of production of this product at the significant producers in Europe and the world.

Material development is oriented in two main directions 1. The development of bainite rails. The production is focused on the medium carbon steels with micro-alloying using Si, Cr, Mo and V. The chemical composition is selected in such a way as to achieve bainite microstructure after a spontaneous cooling in the air immediately after rolling. 2. The development of rails micro-alloyed with Cr, Mo and V to achieve the required hardness of 300, 350 and 400 HB. The development of these steels will not be oriented on the heat treatment but on the adjustment of their chemical compositions. Material analysis of the problem indicates that it will be the rail steel with a super-fine pearlite. The production of new steel grades is focused on the achievement of the required values, in particular, in accordance with UIC, AREMA, EN 13674-1 and CN 12-16C

5


RAILS

T E C H N I C A L D ATA A N D PA R A M E T E R S Basic dimensions and design data

FLAT BOTTOM RAILWAY RAILS

Rails shape 46E1 Dimension

M48

49E1 100ARA-A 50E6

54E2

54E3

54E1 115RE

60E2

60E1

R65

R65-A 136RE 141RE

unit SBB1

S49*

U50* UIC54E* S54* UIC54*

UIC60E2* UIC60*

mm

145

148

149

152.4

153

161

154

159

168.3

172

172

180

180

185.7

188.9

mm

125

120

125

139.7

140

125

125

140

139.7

150

150

150

150

152.4

152.4

mm

65

70

70

69.9

67.4

69.5

70

72.2

69.1

74.3

74.3

75

75

74.6

77.8

mm

14

14

14

14.3

15.5

16

16

16

15.5

16.5

16.5

18

18

17.5

17.5

(kg/m)

46.17

48.4

49.39

49.9

50.9

53.82

54.57 54.77 56.97

60.05

60.21 64.87 64.98 67.41

69.88

(cm2)

58.82 61.69 62.92

63.57

64.84

68.56

69.52 69.77 72.57

76.5

76.7

89.02

Jx (cm4) 1641.1 1745.4 1816

2028

2017.8

2307

2074 2337.9 2740.8 3022 3038.3 3543.1 3547.7 3916 4180.3

Wx (cm3) 217

245.7

248.3

276.4

262.8 278.7 296.4

Height

Bottom width

Head width

Web thickness

Mass 82.64 82.78 85.87

Cross-sectional area

Moment of inertia 234.7 240.3

Section modulus

The equivalent marking according to the old UIC standards. Hot marking of rails shape according to the EN 13674-1 standard or other marking on agreement.

x

x S

y B

FLAT BOTTOM RAILWAY RAILS

6

H

C y

330.4

333.6

359

359.8 388.8

414.5


RAILS

T E C H N I C A L D ATA A N D PA R A M E T E R S Basic dimensions and design data

SWITCH RAILS

Rails shape Dimension

unit Frog S49

Tongue I49

Tongue I65

Tongue UIC60

Tongue XXX

UIC 54A

mm

149

116

147

134

71.5

159

mm

125

145

150

140

89.5

140

mm

70

70.2

75.4

74.5

41.5

72.32

mm

44.5

40

43

44

28

(kg/m)

78.61

63.15

78

72.97

32

65.4

(cm2)

100.14

80.45

99.36

92.95

40.76

83.32

Ix (cm4)

2156.7

1106

2306.1

1727

2513.7

Wx (cm3)

269.1

166.1

280.5

229.7

291.2

Height B– Bottom width C– Head width S– Web thickness G– Mass A– Cross-sectional area

Moment of inertia

Section modulus

S

B

TONGUE RAILS

x

H

x

x

x

H

C y

C y

S y B

y

FROG RAIL S49

7


RAILS

T E C H N I C A L D ATA A N D PA R A M E T E R S Basic dimensions and design data

TRAM RAILS

Rails shape B3

B1

Dimension

unit

H– Height B– Bottom width CTotal head width S– Web thickness C1 – Width of passage head C2 – Groove width G– Mass A– Cross-sectional area Moment of inertia Section modulus

grooved

grooved

entering NT

mm

72

70

180

180

180

mm

156

156

150

150

150

mm

115

116

115

115

114

mm

14

13

14

mm

57

56

55.5

56

mm

35

45

36

42.7

(kg/m)

60.23

53.34

64.5

60.63

74.32

(cm2)

76.72

67.95

82.16

77.23

94.68

Ix (cm4)

318.7

260.7

3546.2

3278.7

4058.7

Wx (cm3)

77.6

62.7

412

369.7

523.2

y

C2

y

C2

x

x

x

x

x S

S y B y B

y B

GROOVED BLOCK RAILS B1 AND B3

8

C

GROOVED RAILS NT1 AND NT3

ENTERING RAILS NT

H

x

C

H

y

NT

grooved block (without web)

H

C

NT 3

grooved block (without web)

C1 C1

NT 1


RAILS

T E C H N I C A L D ATA A N D PA R A M E T E R S Basic dimensions and design data

RAILS FOR MINE AND FIELDS TRACKS

Rails shape Dimension

unit 70/10

80/14

Xa

mm

70

80

125

mm

58

70

110

mm

32

38

58

mm

6

9

12

(kg/m)

10

14

35.64

(cm2)

12.8

17.83

45.4

Ix (cm4)

85.7

154.0

925

Wx (cm3)

24.4

36.9

144.6

H– Height B– Bottom width C– Head width F– Web thickness G– Mass A– Cross-sectional area

Moment of inertia

Section modulus

x

x S

H

C y

y B

RAILS FOR MINE AND FIELDS TRACKS

9


RAILS

T E C H N I C A L D ATA A N D PA R A M E T E R S O ve r v i e w o f t h e m a i n c o nve n t i o n a l a n d u n c o nve n t i o n a l material qualities of rails

I. CONVENTIONAL PROPERTIES

Chemical composition (%) Steel grade

C

Mn

Si

P max.

S max.

V max.

Cr

Mo max.

Rm MPa

A5 % min.

HBW Hardness in the middle of traversing surface HBW

700

UIC860-V

0.40-0.60

0.80-1.25

0.05-0.35

0.050

0.050

680-830

14

900A

UIC860-V

0.60-0.80

0.80-1.30

0.10-0.50

0.040

0.040

880-1030

10

900B

UIC860-V

0.55-0.75

1.30-1.70

0.10-0.50

0.040

0.040

880-1030

9

1100

UIC860-V

0.62-0.82

0.80-1.30

0.30-0.90

0.030

0.030

0.80-1.30

min. 1080

9

R 220

EN13674-1 0.50-0.60

1.00-1.25

0.15-0.60

0.025

0.025

0.030

max. 0.15

min. 770

12

220-260

R 260

EN13674-1 0.60-0.82

0.65-1.25

0.15-0.60

0.025

0.030

0.030

max. 0.15

min. 880

10

260-300

R 260 Mn

EN13674-1 0.55-0.75

1.25-1.75

0.15-0.60

0.025

0.030

0.030

max. 0.15

min. 880

10

260-300

R 320 Cr

EN13674-1 0.60-0.80

0.75-1.25

0.50-1.10

0.020

0.030

0.20

0.75-1.25

min. 1080

9

320-360

STANDARD

AREMA

0.74-0.84

0.75-1.25

0.10-0.60

0.020

0.020

0.010

max. 0.25

0.060

min. 983

10

min. 300

IH

CN12-16C

0.70-0.82

0.70-1.10

0.40-1.00

0.030

0.020

0.010

0.40-0.70

0.050

min. 1014

8

min. 325

3 HB

CN12-16C

0.72-0.82

0.80-1.10

0.10-0.50

0.030

0.020

0.010

0.25-0.40

0.050

min. 983

10

min. 300

Note: • All specified steel grades are vacuum degassed on the RH equipment. • Steel grades different from the above given ones can be provided after an agreement is achieved with the producer.

THE FOLLOWING CONTENTS OF P, S, AI, H 2 ARE CHIEVED P

S

Al

H2

max. 0.020 % max. 0.020% max. 0.004 % max. 2.5 ppm max. 1.5 ppm based on client’s demand

II. UNCONVENTIONAL QUALITIES 1. Rupture toughness K1C 2. Fatigue crack expansion speed K 3. High-cycle fatigue – fatigue limit according to Wöhler curve 4. Residue tension measured in the rail bottom The values of the above given unconventional qualities are fully comparable with the rails manufactured by the leading European producers. TECHNICAL DELIVERY CONDITIONS The deliveries of rails to customers are realized in accordance with the technical terms specified by UIC860, EN 13674-1, ISO 5003 and other international standards based on the customers’ demands. The customers’ demands differing from these standards can be met after the preliminary technical consultation and agreement with the producer.

10


RAILS

SALES

SALES Remtechstroy a Steel Works, joint stock company), is a long-time producer of railway flat-bottom rails in the Bulgaria and EC. A part of rails production has also been exported to a number of countries of Europe and all over the world, such as Belgium, Egypt, the Netherlands, Poland, Hungary, Canada, Romania, Bulgaria, Finland, Croatia, Slovenia, Germany, Turkey, Switzerland USA and Brazil. In last years, in the rolling mills a big attention was paid to the so called RAILS PROGRAM whose aim was to achieve the quality of produced rails comparable with products of leading European producers. A number of partial modifications and innovations of the walking beam furnace (installation of a modern process control system) and the rolling mill (water descaling, lubrication of groves, hot and cold dimension measurement) have been implemented to improve internal and surface quality. The reconstruction of the cooling area makes it possible to cool rails up to 78 m in length. An automatic system of rails marking has been introduced too. In 2006, a device for detection of surface and internal defects of rails was modernized. In the finishing shop, the reconstructions enabling shipment of rails to 75 m long have already been performed and are continued. In 2003, the Rail Finishing Shop was submitted to a major reconstruction, which resulted in an installation of a new Lisinger-system double-sided sawing-and-drilling machine. The reconstruction makes it now possible to simultaneously process rails on two independent lines. Many significant railway companies e.g. DB, SBB, PKP, ŽSR, CN have granted our rails deliveries with many certificates.

11


RAILS

C O N TA C T S

CONTACTS Address your enquiries and questions to the Sales Department of REMTECHSTROY joint-stock company. REMTESTROY GROUP Varna 9000 Industrial zone Troshevo bl.56-A-6 Bulgaria tel.: +359-52-319980 fax: +359-52-319990 www.remtechstroy.eu

12


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Remtechno Varna - 9000 Troshevo, bl.56-A-6 Bulgaria fax: +359/52/319980 e-mail: web@remtechnology.eu http://www.remtechstroy.eu

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• Business & Marketing Director tel.: +359/52/319980 e-mail: business@remtechnology.eu

REMTECHSTROY GROUP CERTIFIKAT 2 REMTECHSTROY GROUP

EN ISO 9001:2000

REMTECHSTROY GROUP

EN ISO 14001


REM Rail EC